Reznor Pilots User Manual

Page 1

Obsoletes Form 701-B

Form P-PILOTS

IMPORTANT

1. Always include complete heater model and serial number so that any specification change can be considered for parts shipment. It can save time and expense.

2. Specifications are subject to change without notice.

3. We reserve the right to substitute functional replacements.

4. Order either by Kit or Component Part No.

Quick Ref eren ce Repla cement Pilo t Kit Selectio n Table

(R efer to FIGURES 1-12, pages 1-4, for illustrations an d comp onent part numbers.)

Heater Infrared

Unit Heaters

Duct Furnaces and Packaged Systems (Also applies to Models with prefix "H")

Heating/ Cooling

Direct Fired

If the replacement pilot changes with the introduction of a Model Series, the Series is indicated in the Selection Table. The Series indicator is on the heater rating plate; it is the suffix number on the Model Size (Ex: SC400-6; "6" is the Series).

Model Designa tion*/Sizes

T, TR -H 50 T, TR-H 75-200 F, B 25-400 FE, BE 25-400 UA, XL, XLB, CXL, CXLB 30-105 XL, XLB, CXL, CXLB 125-400 EEXL, EEXLB, CEEXL, CEEXLB 30-105 EEXL, EEXLB, CEEXL, CEEXLB 125-400 SCA, SCB prior to Series 6 SCA, SCB Series 6 EEDU, HEEDU Series 6 EEDU, HEEDU prior to Series 6 X, XA, XB, XC, XD, XE, XG XJ, PAK, DFAH prior to 9/73

X, XA, XB, XC, XD, XE, XG XJ, PAK, DFAH, CX, CXE , C PAK beginning 9/7 3 SC, SCE Series 6 RX, REB, RXE, RXJ, CRX, CREB, CRXE, RPAK,CRPAK, SC, SCE, SCJ prior to Series 6; RPV, RPVE, RPBE, RPVAK, CRPV, CRPVE, CRPBE, CRPV AK Series 6; RG, CRG, RP, CRP, RGB, CRGB, RPB, CRPB, RGBL, CRGBL, RPBL, CRPBL, SSCBL RPV, RPBE, RPVE, RPVAK RPVJ. CRPV, CRPBE, CRPVE, CRPVAK prior to Series 6 RCG 7-1/2, 10 ton RCG 2 - 5 ton - with vertic a l pi lot

- with hor iz onta l pilot ADF, ADFH w ith hot surface ignition RDF -with spark ignition and flame probe

-with spark ignition and ultraviolet sensor

-w ith hot surface ignition DV with hot surface ignition DFA with hot surface ignition

Natural Propane FIGURE Natural Propane FIGURE

110851 110 852 1 110853 110854 2

110855 110 856 3 110857 110858 4 110859 110 860 5 110861 110862 6

110863 110 864 8 - - 110859 110 860 5 110861 110862 6

Replacement Pilots

M a tch Lit Pilot Kits Spark Pilot Kits**Type of

- - - 110854 1 10854 2

- -

- - - 110853 1 10854 2

- - - 110857 1 10858 4

- - - 110861 1 10862 6

- - - 110853 1 10854 2

- - - 131457 1 31458 8

- - - 110861 1 10862 6

- - - 110865 1 10866 9

- - - 110867 1 10868 10

- - - 110861 1 10862 6

- - - 120048 1 20048 11

- - - 110869 1 10869 11

- - - 110918 1 10918 11

- - - 120048 1 20048 11

Functional

- 110853 110853 2

131457 1 31458 8

110861 1 10862 6

** Spark pilot kits for all indirect-fired products are for use with Model G60, G65, G67, or G770 ignition controllers only. Pilot kits

are not available for other spark ignition systems used on indirect-fired products.

Pilot Kits and Components

FIGURE 1 - Vertical Match-

Lit Pilot for Models F and B

Replacement Natural Gas - P/N 110851 Pilot Kits Propane Ga s - P/N 11 08 5 2

Code

103034

Component Description

P/N

Nat u ral G a s P ilot Assembly with o r ifice, pilo t tubing, an d

96360

thermocouple; less fitting (Johnson #J994HKA-9731-715) P r opan e Gas P ilot Assembly with o r ifice, pilo t tubing, an d

96361

thermocouple; less fitting (Johnson #J994HKA-9733-410) Natural Gas Orifice only, Johnson #9731-715 (brass) Prop ane Gas Orifice only, Johnson #9733-410 (black)

98695

Pilot T ubing, 1/8" x O.D. x 18" long, Johnson #B10499-995-11

98698

Compression Fitting, FTG 75 (2 required w h en replacing pilot t u bing)

97572

Thermocoup le, 24", #K15FA-24D

Form P-PILOTS, 131133R3, Page 1

Page 2

FIGURE 2 - Vertical Spark

)

Nut with breakaway ferrule (2 required

)

Pilot for Unit Heater Models F/FE/B/BE, Infrared Models TR/TR-H, and Duct Furnace Models EEDU/HEEDU Series 6

Replacement Pilot Kits

Models F/FE/B/BE Model TR 50 Model s TR 75-20 0 M o dels (H )EEDU Series 6

Natural G as Natural G as Natural G as -

Natural G as -

P/N 110853 P/N 110854 P/N 110853

P/N 110853

; Propane Gas ; Propane Gas ; Propane Gas -

; Propane Gas -

P/N 110854 P/N 110854 P/N 110853

P/N 110854

Code P/N Appl ication Gas Component Description

1 97534

97535

2 103034

F/FE/B/BE and (H)EEDU Series 6

Natural

TR 75-200 Natural & Propane F/FE/B/BE and (H)EEDU Series 6

Propane

TR 50 N a t ural & Propane F/FE/B/BE and (H)EEDU Series 6

Natural

Pilot As sembly with orifice, pilot tubing, and flame rod; less flame sensor l ea d and fitting (Johnson #J982HKW-9731-713 Pilot As sembly with orifice, pilot tubing, and flame rod; less flame sensor l ea d and fitting (Johnson #J982HKW-9733-410) Orifice only, Johnson # 9731-713 (brass)

TR 75-200 Natural & Propane

98695

F/FE/B/BE and (H)EEDU Series 6

Propane

Orifice only, Johns on # 9733-410 (black)

TR 50 N a t ural & Propane

3 98698

Pilot Tubing, 1/8" OD x 18" lg, Johnson #B10499-99-11

97572

4 98697 5 97575

F/FE/B/BE /TR and (H)EEDU Series 6

N a t ural & Propane

C o mpressi o n Fitt ing, FTG75 (2 require d when replacing pil ot tubing) Flame Ro d, Johnson #Y75AA-10 Flame Sensor Lead, 21 "

FIGURE 3 - Horizontal Match Lit Pilot for Models UA, XL, XLB, CXL, CXLB 30 - 105

Replaceme nt Natural Gas - P/N 110855 Pilot Kits Propane Gas - P/N 110856

Code

Component Description

P/N

Natural Gas Pilot Assembly with

40964

orifice; less pilot tubing, less thermocouple (Baso #J999HKA4213 Propane Gas Pilot Assembly with

40420

orifice; less pilot tubing, less thermocouple (Baso #J999HKA4207 Natural Gas Orifi ce only, #4213

40966

Propane Gas Orifice only, #4207

40965

Pilot T ubing, 22" long

5145 9664

when replacing pilot tubing) Thermocouple, TC2-24"

84761

FIGURE 5 - Horizontal Match Lit Pilot - Starting 9/73 for Models X, XA, XB, XC, XD, XE, XG, XJ, PAK, DFAH, HX, HXE, CX, CXE, HCX, HCXE, CPAK; Also XL, XLB, CXL, CXLB 125400

Form P-PILOTS, Page 2

Replacement Natural Gas - P/N 110859 Pilot Kits Pro pane Gas - P/N 110860

Code

FIGURE 4 - Horizontal Spark Pilot for Models EEXL, EEXLB,

CEEXL, CEEXLB 30 - 105. May also be used on XL, XLB, CXL, CXLB when equipped with G60, G65 or G67 ignition controller (with or without

Serial No. Suffix "B")

Replacement Natural Gas - P/N 110857 Pilot Kits Propane Gas - P/N 110858

Code

4 5

Above pilot replaces Baso #J987HKW, natural gas P/N 50449 and propane gas P/N

51330. Also replaces General Controls #26C27113 with 16" high tension lead, natural gas pilot P/N 64463 and propane gas P/N 64464; and General Controls #26C27113 with 24" high tension lead, natural gas pilot P/N 73614 and propane pilot P/N 73615.

Component Description

P/N

17890

Natural Gas Pilot with orific e; less pilot tubing, l ess thermocouple (Baso #J963HXA6218

46136

Propane Gas Pilot with orifice; less pilot tubing, l ess thermocouple (Baso #J963HXA421 Natural Gas Orifice on ly , #6218

46392

Prop ane Gas Orifice only , #4211 This pilot

42089

Pilot Tubing, 26" lg for X Series may be used

7671 9664

Nut with breakaway ferrule (2 required when re placing pilot tubing) Pilot Tubing, 22" lg for XL, XLB, CXL, CXLB 125-400 GC

5145

Nut with breakaway ferrule (2 required when replacing pilot tubing) #26C23114.

9664

Thermocou p le TC2 , 24" lg for X Series

84761

Thermocouple TC2, 18" lg for XL, XLB, CXL, CXLB 12 5-400

84760

Component Description

P/N

Natural Gas Pilot Assy with orifice and high tension lead; less pilot

93971

tubing, less flame probe, less sensor lead (Baso #J983HKW7715) Propane Gas Pilot Assy with orifice and high tension lead; less pilot

93972

tubing, less flame probe, less sensor lead (Baso #J983HKW4709) Natural Gas Orifice only, #7715

93973

Propane Gas Orifice only, #4709

93974

Pilot Tubing, 22" long

5145

Nut with breakaway ferrule (2 required when replacing pilot tubing)

9664

Sensor lead, 16" lg

50450

Flame probe, Y75BA

43594

in place of

Page 3

FIGURE 6 - Horizontal Spark Pilots for Models

;

Propane Gas Pilot Assy with orifice, high tension lead, flame probe;

)

Nut with breakaway ferrule

XL, XLB, CXL, CXLB 125-400 EEXL, EEXLB, CEEXL, CEEXLB 125-400; EEDU, HEEDU prior to Series 6 Starting 9/73 for X, XA, XB, XC, XD, XE, XG, XJ, PAK, DFAH, CX, CXE, CPAK RX, REB, RXE, RXJ, CRX, CREB, CRXE, RPAK, CRPAK; SC, SCA, SCB, SCE,

SCJ Prior to Series 6; RPV, RPVE, RPBE, RPVAK, CRPV, CRPVE, CRPBE, CRPVAK Series 6; RG, CRG, RP, CRP, RGB, CRGB, RPB, CRPB, RGBL, CRGBL, RPBL, CRPBL, SSCBL

RCG 2 through 5 ton with horizontal pilot

NOTES:

– Horizontal spark pilots for ignition systems other than

G60, G65, G67 and G770 are no longer available. – Kits also apply to models listed with the prefix "H" *Included in all kits. Used only with the above models

equipped with any Model G60 ignition controller, a Model G67BG-2, or a Model G67NG-2. Not used with ignition controller Models G67BG-5 and G770NGC-4. See Instructions on page 4.

– This pilot replaces Baso #J991HXW, natural gas

P/N 45150, propane P/N 45141; #J994HXW, natural

gas P/N 47303, propane P/N 47384. May be used as

a substitution for J993HXW and J999HXW.

*See instructions on page 4.

Replacement Natural Gas - P/N 110861 Pilot Kits Propane Gas - P/N 110862

Code

Comp onent Description

P/N

Natural Gas Pilot Assy with orifice, high tension lead, flame probe

61145

less pilot tubing, less flame sensor lead (Baso #J992HXW7221)

61146

less pilot tubing, less flame sensor lead (Baso #J992HXW9817)

5* 6*

112647 112648

Natura l Gas Orif ice only, #7221

63088

Propane Gas Orifice only, #4209

37801

Pilo t Tubing, 22" lg

5145

Nut with breakaway ferrule (2 required when repl ac ing pilot tu bing

9664

Sensor lead, 16" lg

50450

Crimp-on, 90 90o Boot Ter minal Protect or

Rajah terminal connector

FIGURE 7 - Vertical Spark Pilot for Models SC, SCA, SCB, SCE Series 6

Replacement Pilot Kits Code P/N Component De scription

1 125251

125671

2 103034

126024

3 98698

4 126104 5 126101 6 125401

Natural Gas Propane G as -

Natural Gas Pilot Assy with orifice, pi lot tubing and flame probe; less fl ame sensor lead and fitting (Johnson #J981H KW-9731-713 Pr opane Gas Pi lot Assy wi th or ifice, pilot tubing and flame probe; less fl ame sensor lead and fitting (Johnson #J981HKW-9715-413) Natural Gas Orifice only, Johns on # 9731-713 (brass) Pr opa ne Gas Orifice only, Johnson # 9715-413 (black) Pilot Tubing, 1/8" OD x 18" lg, Johnson #B1049 99-11 Compression Fitting, FTG75 (2 required when

97572

replacing pilot tubing) Flame Probe, J o hn son #Y75AA- 2 Auxiliar y flame probe w/bracket, J/C Y5 -GB-1 (2) Sensor lead assy, 18 ga x 14", 150°C

P/N 131457

P/N 131458

FIGURE 8 Vertical Match Lit Pilot for Models X, XA, XB, XC, XD, XE, XG, XJ, PAK, DFAH prior to 9/73

Replacement Natural Gas - P/N 11086 Pilot Kits Propane Gas - P/N 11086

Code

Component Description

P/N

Natural Gas Pilot Assy

9661

with orifice; less pilot tubing, less thermocouple (Baso J915HHA6221) Propane Gas Pilot Assy

30126

with orifice; less pilot tubing, less thermocouple (Baso J915HHA4211) Natural Gas Orifi ce only,

44048

#6221 Propane Gas Orifice only,

42089

#4211 Pilot Tubing, 26" lg

7671 9664

(2 required when replacing pilot tubing) Thermocouple, TC2, 24" l

84761

FIGURE 9 - Vertical Spark Pilot for Models RPV, RPBE, RPVE, RPVJ, RPVAK, HRPV, HRPBE, HRPVE, CRPV, HCRPV, CRPBE, HCRPBE, CRPVE, HCRPVE; CRPVAK prior to Series 6 and RCG 7-12/, 10 ton equipped with G60 or G67 ignition Controller

NOTE: Vertical spark pilots for ignition systems other than G60 and G67 are no longer available.

*See Instructions, page 4.

Replacement Natural Gas - P/N 110865 Pil o t Kits Propane G a s - P/N 11 08 66

Code

3 4 5

6* 7*

112647 112648

Component Descript ion

P/N

Nat ural Ga s P ilo t Ass y w ith o r if ice , high t e nsion le ad; les s pilo t

41775

tubing, less flame probe, les s sensor lead (Baso #J999HHW6221) P r opan e Gas Pilot As sy w ith o r if ice , h igh ten sion lead ; less p ilot

44673

tubing, less flame probe, les s sensor lead (Baso #J999HHW4209) Natu ral G a s Or i f ic e on ly , # 62 21

44048

Propane Gas O rifice only , #4209

37801

Sen sor lea d a sse mbly , 16" lg an d 21" lg w ire s (n ot illu strated )

92848

(2) Flame probe Y75BA -3

43594

Bracket Y59DD-1

44678

Crimp-on, 90

Bo o t Term in al P r o tect or

P ilo t tubing 2 6 " lg (no t illu st r a ted )

7671

N ut w ith breakaway ferrule (2 required w h en replacing pilot t u bing)

9664

Rajah term inal con n ec tor

Form P-PILOTS, 131133R3, Page 3

Page 4

FIGURE 10 - Vertical Spark Pilot for Models RCG 2 - 5 ton with Vertical Pilot

*See instructions below.

FIGURE 11 - Pilot Systems used on Direct-Fired Models RDF/

Replacement w/Flame Probe - P/N 110869 Pilot Kits w/Ultraviolet Sensor - P/N 110918

ADF/ADFH/DFA/DV

Replacement Natural Gas - P/N 110867 Pil ot Kits Propane Gas - P/N 110868

Code

3 4

5* 6*

P/N

87936

87937

Component Description

P/N

Natural Gas Pilot with orifice, high tension lead and built-in flame probe; less

47484

pilot tubing, less sensor lead (Baso #J993HHW6221) Propane Gas Pilot with orifice, high tension lead and built-in flame probe; less

47485

pilot tubing, less sensor lead (Baso #J993HHW4211) Natural Gas Orifice only, #6221

44048

Propane Gas Orifice only, #4211

42089

Sensor lead, 38" lg

44183

Pilot tubing 26" lg

7671

Nut with breakaway ferrule (2 required when replacing pilot tubing)

9664

112647

Crimp-on, 90

112648

1, 2, 4)

w/Hot Surface Ignition - P/N 120048

Codes 5, 6, 7, and 8) Co

Pilot Supply Connection including: (1) brass elbow,

P/N 93388 P/N 95189

Spark Plug, 27750-1-31, Maxon #18075

Boot Terminal Protector

mponent Description

; (3) connec tors,

Flame Probe, Auburn AA67-7892-1 - Standard on unit s w ith date code prior to ANI ( 9/88)

5 6

122840

134706*

121865 121730

Ultraviolet Minipeeper, #C7027A - Standard on units

89411

with date code from ANI (9/88) through AVB (2/96) optional on prior units Pilot Plate and Tubing Assembly ADF/ADFH*; DFA; Flame Sensor, J/C #Y75MK-1D DV; and RDF with Ignitor, Norton #401E Pilot Bushing

Rajah terminal connector

(Includes Codes 1, 2, 3)

(Includes Codes

(Includes

P/N 95188

; (1) long nut,

RDF with spark pilot RDF with spark pilot

ADF/DFA/RDF/DV with

hot surface ignition

Applies to

RDF Models

with a spark pilot

and either a probe or

ultraviolet

flame sensor

hot surface

ignition

Hot Surface Ignition Kits below include all components needed to change RDF units from a

*P/N 135435 is a replace-

ment flame sensor only kit for ADF/ADFH units manufactured prior to 11/94.

spark pilot system with either a flame probe or ultraviolet sensor to hot surface ignition

- for an RDF unit with a 200VA Transformer - P/N 146268

- for a 115V RDF unit with an 80VA transformer - P/N 146318

- for a 208V RDF unit with an 80VA transformer - P/N 146319

- for a 240V, 480V, or 575V RDF unit with an 80VA transformer - P/N 146320

NOTE: Model, Serial No., and Wiring Diagram No. MUST be provided when ordering these kits.

Instructions for connecting ignitor lead on replacement spark pilots to Model G60 and G67 ignition controllers (applies to Pilot Kits in FIGURES 6, 9, and 10):

Crimp-on, 90° Rajah Terminal Connector, P/N 112647

Protective Boot, P/N 112648

Effective with replacement pilots purchased 9/91, these parts are required (in the kit or separately) when the replacement pilot is for heater Models listed in FIGURES 6, 9 and 10 equipped with a Model G60 or G67BG-NG-2 ignition controller. (Note: These parts are not required when the ignition controller is a Model G67BG-5 or G770NGC-4.)

1. Identify the ignitor wire attached to the pilot electrode. Slip the 90° protective boot on to the wire, as illustrated è.

2. On the "open" leg of the 90° crimp-on terminal (P/N 112647), locate a flat, triangular spike tab punched in the metal. With the tip of a small, straight screwdriver, force the spike tab toward the inside of the connector. Straighten the tab to a vertical position.

3. Insert the ignitor wire into that same connector leg (just to the 90° bend) and push the wire onto the protruding spike tab, making sure that the tab penetrates the insulation. (Do not strip the ignitor wire.) Using a crimping tool or pliers, squeeze the sides of the terminal to form a "C" shape. The ignitor wire should now be firmly held by the terminal.

4. Slide the protective boot over the terminal. Holding the boot, attach the 90 Rajah terminal to the ignitor lead Rajah connector on the Model G60 or G67BG/ NG-2 ignition controller.

Step 4 - Attach to Ignition Controller

Step 2 & 3 - Attach 90°, Crimp-on

Step 1 - Slip Boot over

Install boot

and terminal

on ignitor wire

www.RezSpec.com; 800-695-1901

Form P-PILOTS, Page 4

0514 P-PILOTS (Version .3)